Mobius Institute
Reliability Improvement

A substantial percentage of reliability improvement programs fail, not because good intention and effort were lacking, or that your reliability champion wasn’t competent, but rather because success depends on unfailing management understanding and support, proper skills training, application of a solid defect elimination program and plant floor awareness and buy-in that is needed to shift from a legacy thinking, to a reliability-rewarded culture of change. At Mobius Institute, we take these challenges head-on and provide plants with broad-based education in reliability application and awareness, proper program management and skills improvement resources.

Managing Reliability Improvement

The Roadmap to Reliability

Everyone needs to understand the elements and application of a proper Plant Empowered Reliability Improvement (PERI) program. Successful programs are built on a manageable roadmap that guides a plant through planning, assessment, strategy application and precision maintenance techniques. Jason Tranter describes the “Roadmap to Reliability” which is used to guide you towards a having a more reliable plant. Download the following Reliability Roadmap diagram, to better follow along with this valuable training video.

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Reliability Roadmap Diagram

The Reliability Roadmap summarizes the four stages to achieve reliability improvement. Stage One outlines the preparation required to initiate a program, from selecting the right leadership to obtaining the proper training. Stage Two is where you begin to understand your assets, their criticality and failure modes. Stage Three identifies the appropriate reliability strategies and which respective maintenance strategy that will be applied. And finally, Stage Four covers Precision Maintenance techniques that consider everything from asset procurement to RCFA. This download is a recommended as material to follow while watching “The Roadmap to Reliability” video above.

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Plant Reliability: Pockets of Knowledge

How do make sure that everyone is on the same page - all pulling in the same direction to achieve improved reliability success? With merely "pockets of knowledge" your reliability initiative won't be sustainable. This iLearnReliability presentation examines this topic, and provides suggestions to avoid this common pitfall.

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iLearnReliability Presentations

Improve your Plant Reliability / Introduction to iLearnReliability™

Everyone contributes to unreliability, therefore everyone must be trained to improve your plant's reliability. This overview presentation describes how you can take meaningful steps toward sustainable reliability improvement by subscribing to iLearnReliability. Plant-wide training for everyone at your plant from top management, reliability and condition monitoring program managers, skills training for the craftsmen and plant-wide awareness for everyone on the plant floor.

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iLearnReliability – Reliability Improvement Training Overview

Why you need iLearnReliability to achieve a higher level of reliability via the “Plant Empowered Reliability Improvement (PERI) program: successful condition based maintenance and effective precision maintenance through training and culture change.

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What is Plant Empowered Reliability Improvement?

The majority of people within every plant would prefer to have reliability as their top priority, because with reliability comes safety, profitability, job security, a less stressful workplace and job satisfaction. Everyone within a plant would prioritize reliability if they were given the opportunity, but three things stop them; leadership from management, buy-in from co-workers and the skill to do the job correctly. This presentation takes a look at these issues.

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The Solution to the Post Conference Blues

What to do with the inspiration and determination gained during the maintenance and reliability conferences or training courses. Too often, once attendees return from engaging and inspiring conferences, this momentum is not transferred to the workplace and we find ourselves back to our routines.

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What do Donald Rumsfeld and Mark Twain have to do with Reliability Improvement?

This lighthearted presentation looks at Known Knowns, Known Unknowns and Unknown Unkowns in respect to reliability improvement. It’s all about what you know and what you don’t know.

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The Plan behind the Training, as described by the Reliability Spectrum

Before you subscribe to iLearnReliability, it is important that you understand the strategy that we are teaching via the lesson modules. The best way to do that is via the Reliability Spectrum. iLearnReliability provides training on specific precision skills techniques and other activities designed to improve reliability. In addition to the detailed skills training, training is also provided to upper management (Management Briefings), program management (Management Training), and plant-floor personnel (Toolbox Talks) to provide awareness training on each of the techniques and the philosophy of reliability improvement.

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iLearnReliability Information

iLearnReliability Brochure

Learn more about how reliability improvement is achievable and sustainable through management, condition monitoring and precision maintenance training, and plant-wide awareness.

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iLearnReliability Training Module Details Brochure

iLearnReliability™ Plant Empowered Reliability Improvement (PERI) training module details for plant management, reliability program managers, skills training and awareness training for plant floor crafts and operators.

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Contact

Mobius Institute, founded in 1999, is a worldwide provider of Reliability Improvement, Condition Monitoring and Precision Maintenance education to industrial plant managers, reliability engineers and condition monitoring technicians, allowing plants to be successful in implementing Reliability Improvement programs through delivery of more easily understandable and comprehensive training. Mobius Institute has offices in Australia, Belgium, Costa Rica and the United States with training centers in 50 countries.

Phone: (877) 550-3400
Web: http://www.mobiusinstitute.com
Email: learn@mobiusinstitute.com

Plant Services Special Reports

When a desire to improve reliability takes shape, it’s very common that few will share the vision. One or more reliability programs may be implemented and pockets of excellence may be achieved, and those efforts will surely provide a return on investment, at least for a while. Unfortunately, this is not a viable means to achieve true reliability. Much like safety has become ingrained in the industrial culture, reliability requires a culture change. It must be fostered company-wide through training, supported with buy-in at all levels, practiced habitually, and remain top of mind long after the initial push. With the right tools, companies can develop a comprehensive reliability improvement strategy, deliver targeted training throughout the organization, and maximize the benefits of the program by securing a lasting culture change. Improved profitability and increased personnel and environmental safety are among the more compelling benefits of achieving reliability success.

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Too often, plants accept an inadequate level of equipment reliability as normal, and expect that their repair teams will be deployed on a regular basis. This view has a legacy that runs deep in the psyche of managers, the maintenance/repair workers and the plant floor operators. While condition monitoring has allowed plants to identify machine faults earlier in their life cycle and, in most cases, before catastrophic failure, it does nothing to improve machine reliability. This special report looks at how the right training and a broad awareness can create an environment where a common-sense, team-led approach can take root and change the plant's psyche to result in sustainable reliability improvement.

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Webinars

Contamination Control: The Key to Gearbox Reliability

If you are not controlling contamination of your lubricants, then you cannot achieve the maximum service life of your rotating machinery or your lubricants. Using lots of 3D animations and animated illustrations, this presentation will focus on gearbox lubrication, explaining why contamination reduces the life of the gears and bearings (and the oil itself), how much the service life is reduced, how to reduce contamination, and how to remove unavoidable (and avoidable) contaminants.

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Reliability Improvement: Adopting a Defect Elimination and CBM Program to Achieve the Lowest Life Cycle Costs

In this presentation we discuss the most important elements of a successful reliability improvement program; condition based maintenance and defect elimination initiatives. A proper program will achieve the lowest asset life cycle costs through:

  • Plan: Building a Reliability Steering Committee to develop Asset Criticality Ranking, assess the failure modes and consequences, and design the asset reliability strategy
  • Prevent: Taking steps to stop defects from being imported into the plant and being introduced to the machine during maintenance and operation
  • Monitor: Planning maintenance based on condition rather than operating hours
  • Improve: Utilizing RCFA to determine why an asset failed and make changes to avoid it from reoccurring

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Reliability Improvement: Establishing the Asset Criticality Ranking

Without the Asset Criticality Ranking, your reliability improvement (and work management) program is flying blind.

It is essential that the reliability improvement program begins with the development of an asset criticality ranking that everyone (maintenance, production, EHS, quality, and other "stakeholders") agree to. The criticality ranking is used to determine the maintenance and reliability strategy, the maintenance/work order priorities, spares management, resource allocation, and more. But developing the ranking with full agreement is challenging. This Webinar proposes an approach that will work.

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Reliability Improvement: Precision Lubrication & Contamination Control

The presentation is one module of the Toolbox Talks (TT) series within the iLearnReliability training collection. It explains how important lubrication is, and highlights critical it is that the lubricant is in a fit state with the correct viscosity and other properties and free of contaminants. The focus is rolling element bearing lubrication, and the 3D animations make it clear that contaminants damage the bearing surface and too much or too little lubrication will greatly reduce the life of the bearing.

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Reliability Improvement: Manager Briefing - the Roadmap to Reliability

The presentation is one module of the Manager Briefings (MB) series within the iLearnReliability training collection. A discussion for plant managers, it presents how to implement Plant Empowered Reliability Improvement (PERI); explaining the elements of transforming your plant from reactive to reliable.

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Condition Monitoring, CBM and precision maintenance benefits

This one hour presentation by Jason Tranter summarizes four maintenance strategies then looks more closely at condition monitoring and predictive maintenance. The benefits of precision maintenance are described and then illustrated. Along the way the presentation discusses the famous bathtub curve and introduces OEE.

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Condition Monitoring and Reliability

In this presentation, Jason Tranter discusses how condition monitoring techniques can be utilized to improve the reliability of rotating machinery. The presentation begins with an overview of the benefits of condition monitoring - the early detection of fault conditions. The presentation continues by describing how condition monitoring can be utilized to detect situations that may lead to bearing and other forms of machinery failure. And finally, why it is so important to have an acceptance testing program at your plant, and provides some basic guidelines on how the acceptance testing program can be established.

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